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Interested in picking up this awesome Mustang EcoBoost Intercooler? Check out our product page for more details!

Mishimoto Mustang EcoBoost Performance Intercooler

An Interesting Discovery

At this point, our intercooler project took an interesting turn. We wanted to develop a cooler, including going through the process of 3D design, and working up a prototype unit. That said, we had a new idea to get some early baseline testing for core design.

After swinging by our sample room, we retrieved the cooler shown below.

Mishmoto E90 intercooler

Mishmoto E90 intercooler

This is the intercooler we offer for the E90 BMW 335I. It is a twin-turbo coupe/sedan that makes power from an inline 6-cylinder engine to the tune of around 300 hp. Basic upgrades and tuning have been known to launch power into the mid 300s at the wheels.

The Mustang EB is rated similarly (excluding the two extra cylinders), so it would be a nice starting point to use for designing our core. We saw incredible temperature drops

Interested in purchasing our Mustang EcoBoost intake system? Check out more details on our product page linked below!

Mishimoto Ford Mustang EcoBoost Performance Air Intake

Last time we covered the design of our intake pipe and left you with a look at our airbox design in the form of a rendering. It's time to show you how we developed this component.

First, we started with some steel and began selecting mounting points for attaching our box. Once we found these points, we pulled out the welder and began fabricating a prototype.

Fabricating Mustang airbox

Fabricating Mustang airbox

We then constructed a lid to fully seal the filter from engine bay temperatures.

Fabricating Mustang airbox

Fabricating Mustang airbox

Now that we had a basic design, our engineering team put this into Solidworks to create the awesome 3D renderings shown below.

Mishimoto intake system rendering

Mishimoto intake system rendering

We didn't stop here! To ensure the perfect fitment of this component, we used our 3D

Interested in purchasing our Mustang EcoBoost intake system? Check out more details on our product page linked below!

Mishimoto Ford Mustang EcoBoost Performance Air Intake

With the stock unit out of the way we could begin developing our intake piping. We would be starting at the turbocharger and working outward to an airbox near the stock location.

Using the dimensions from the stock unit, we developed a 3D model of an inlet hose that would be constructed from a silicone material. After completing the model, we produced a unit using our 3D printer.

Printing 3D model of intake inlet tube

Because this piece is larger than the bay of our 3D printer, it was constructed from three sections that were glued together. Check out the final design!

3D model of intake inlet tube

3D model of intake inlet tube

This unit has a shape that is similar to the factory unit. We also incorporated both the BPV and the CCV ports, which allow for connection to the OEM pieces. This unit will install just like the

Interested in picking up this awesome Mustang EcoBoost Intercooler? Check out our product page for more details!

Mishimoto Mustang EcoBoost Performance Intercooler

With nearly a 30-year gap between the old and new turbocharged 4-cylinder Mustang, some things are bound to change. The new Mustang features many interesting advances in technology, including direct injection, a twin-scroll turbocharger, a DOHC cylinder head with variable valve timing, and a newly designed intercooler. The 80's model featured a top-mount intercooler that was fed cool air through a functional hood scoop. This was pretty slick stuff for the days when the Walkman revolutionized how we listen to music, and "the Clapper" paved the way for a new level of laziness.

The new Mustang features a very efficient front-mounted intercooler that fits right below the radiator. A fresh stream of airflow passes through the tube-and-fin core and works to combat high intake temperatures.

We've been highlighting our progress on the

Interested in picking up this awesome catch can kit? Check out more details on our product page linked below!

Mishimoto Ford Mustang EcoBoost Baffled Oil Catch Can

When we left you last time, we had equipped our Mustang up with our prototype dual-can setup, and we sent the vehicle out for some road use. Since we would be testing other components (intake and intercooler) at the same time, dyno pulls would also be conducted with this setup installed.

After just 300 miles of road use, this is what we found.

PCV catch can contents

PCV catch can contents

It's Interesting that our breather-side catch can looked fairly empty after our road testing.

Breather catch can contents

The can above was bone dry. We continued to accumulate miles, and strangely enough, this can still did not collect any fluid. Although it had a scent of fuel and oil, accumulation was nonexistent.

With our results in, we came to the conclusion that our kit would include only the PCV-side catch can. We would never want to

Interested in purchasing our Mustang EcoBoost intake system? Check out more details on our product page linked below!

Mishimoto Ford Mustang EcoBoost Performance Air Intake

Fresh Air

An intake is a great way to dip your feet into the aftermarket modification pool. Easy to install, instant results, and a neat sound are key draws for upgrading this particular component. Depending upon the form of engine management and airflow sensor use, slight power gains are often a result of upgrading to a less restrictive system.

The new EcoBoost Mustang is slightly different than other intake projects we have tackled, which have been mainly Subaru MAF-style intake systems. As you know, the EB is a MAP-based system, so intake upgrades normally make less of an impact on power but still provide that same intake noise/growl you expect. Additionally, upgrading the intake for greater flow will provide less restrictions for vehicles that are further upgraded (exhaust, tune, turbocharger, etc.).

With all this

Interested in picking up this awesome catch can kit? Check out more details on our product page linked below!

Mishimoto Ford Mustang EcoBoost Baffled Oil Catch Can

Mishimoto 2015 Mustang EB

Last time, we selected the mounting brackets for our dual can setup. As mentioned earlier in our thread, we would be performing real-world road testing to determine if both lines accumulate byproduct. Our next task was to develop and install some lines for testing.

Line Fabrication

First, we tackled the breather line, which ties in between the valve cover and the turbocharger inlet pipe. Our line routes from the breather port around the rear of the engine to the catch can. The return line follows a similar path back to the inlet pipe. You will notice we have retained the stock pressure sensor.

Breather line mockup

Breather line mockup

Breather line mockup

These lines even fit with the stock engine cover!

Breather line mockup

Breather line mockup

A few interesting things to note about the hoses. First,

Interested in picking up this awesome catch can kit? Check out more details on our product page linked below!

Mishimoto Ford Mustang EcoBoost Baffled Oil Catch Can

Now that we had a good idea of where to start with this project, our team began by selecting the appropriate catch can for the Mustang.

Catch Can Selection

We have two options in catch cans. Our standard baffled oil catch can is shown below.

This innovative catch can features a slew of high-quality CNC-machined components. The unit utilizes thread-in fittings, an internal baffle, and a bronze 40-micron filter to separate the particles. We have had a ton of success offering this product as a universal catch can. One thing that may hold us back from using this component in the Mustang 2.3L is the general footprint. This is a large catch can and provides a massive volume for oil collection. Although the engine compartment of the 2.3L is rather spacious, we would need to fit two of these cans under the hood. This could affect the

Interested in picking up this awesome catch can kit? Check out more details on our product page linked below!

Mishimoto Ford Mustang EcoBoost Baffled Oil Catch Can

Mishimoto 2015 Ford Mustang EcoBoost

Does it need a catch can?

This question is on the minds of many vehicle enthusiasts. If it doesn't add power, why would I want it? Why should I waste my money on it? All valid questions here. True, a catch can install will not add power to your vehicle, but that does not negate its function as a beneficial component for your vehicle.

Let's jump into the basic benefits of a catch can. Its primary function is to separate and collect oil and fuel by-products from your vehicle's crankcase ventilation (CCV) system before they reenter the intake tract. If these by-products are not captured, they move into the intake system, which can cause several problems. But first, let's learn a bit about CCV systems and how they function to improve emissions and protect our environment.

Without going into too

Interested in purchasing our Mustang EcoBoost oil cooler kit? Check out more details on our product page linked below!

Mishimoto Ford Mustang EcoBoost Oil Cooler Kit

Prototype Testing Equipment and Setup

Time for the fun part: product testing! Once we had the brackets mocked up, our lines in place, and our sandwich plate installed, it was time to install our sensors to collect data. We would be collecting both temperature and pressure data for the stock setup and for our installed kit. Check out a shot of our testing sensors installed!

Mishimoto temperature sensors installed

And then our sensor wires are routed back into the cabin.

Mishimoto temperature sensors in vehicle cabin

Laptop setup for testing

Everything was now prepared for a few runs on the highway! Our testing conditions are listed below.

Ambient Temperature: 70°F-75°F (21°C-24°C)

Sensors: PLX temperature and pressure sensors

Variable: Mishimoto 19-row Stacked-Plate Oil Cooler Kit (non-thermostatic)

Process: Vehicle was heat-soaked